Schrack Technik PQC User manual

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USER MANUAL
POWER FACTOR CORRECTION
Power Quality Controller PQC

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Contents
1 SAFETY 7
1.1 OBJECTIVE 7
1.2 SAFETY INSTRUCTIONS 7
1.3 INTENDED USE 8
1.4 IMPROPER USE 8
1.5 REPAIR 9
1.6 SYMBOLS USED 9
2 TECHNICAL DATA 10
3 INSTRUMENT DESCRIPTION 14
3.1 FUNCTION 14
3.2 REGENERATION 14
4 MOUNTING THE INSTRUMENT 15
4.1 SUITABLE LOCATION 15
4.2 INSTALLING THE INSTRUMENT 15
5 INSTALLATION 17
5.1 ELECTRICAL CONNECTIONS 17
5.2 EARTH CONNECTION 18
5.3 SUPPLY VOLTAGE 19
5.4 VOLTAGE MEASUREMENT 20
5.5 CURRENT MEASUREMENT 21
5.6 OUTPUT RELAYS (CONTROL OUTPUTS) 23
5.7 CONNECTION DIAGRAMS OF ALL PQC INSTRUMENT TYPES 24
5.7.1 CONNECTION DIAGRAM:VERSION PQC 1202401-XX 24
5.7.2 CONNECTION DIAGRAM:VERSION PQC 1202403-XX 25
5.7.3 CONNECTION DIAGRAM:VERSION PQC 0602401-XX 26
5.7.4 CONNECTION DIAGRAM:VERSION PQC 1204801-XX 27
5.7.5 CONNECTION DIAGRAM:VERSION PQC 1204803-XX 28
5.7.6 CONNECTION DIAGRAM:VERSION PQC 0614801-XX 29

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5.7.7 O PTIONS FOR CONNECTING THE AUX POWER SUPPLY FOR PQC XXX480X-XX VERSIONS 30
6 COMMISSIONING (INITIAL START-UP) 31
6.1 A LARM FUNCTION 31
6.1.1 L IST OF ALARMS AND MESSAGES 31
6.2 S AFETY PRECAUTIONS BEFORE START - UP 32
6.3 F UNCTIONAL CHECKOUT 32
6.4 C ONFIGURATION 32
6.5 A UTOMATIC COMMISSIONING 32
6.5.1 A UTOMATIC CONNECTION IDENTIFICATION 33
6.5.2 A UTOMATIC IDENTIFICATION OF THE CONNECTED CAPACITOR STAGES 33
6.5.3 C ALCULATION OF C / K 34
7 DESCRIPTION OF THE MENU 35
7.1 M ENU OVERVIEW 36
8 MAIN MENU 38
8.1 PQC INITIAL START - UP 39
8.1.1 L ANGUAGE SELECTION ON START - UP 39
8.1.2 S TART - UP 41
8.2 PQC OVERVIEW 41
8.2.1 D ISPLAYED PARAMETERS 42
8.3 C ONTROL DIAGRAM 44
8.3.1 S CALE 44
8.4 M ANUAL CONTROL 45
8.4.1 S TAGES MENU 46
8.5 S ETTINGS 47
8.5.1 S ETTABLE CONTROL PROFILES 47
8.5.2 T YPICAL CONTROL PROFILE APPLICATIONS 47
8.5.3 G ENERAL SETTINGS 54
8.6 I NFO / STATUS 60
8.6.1 PQC STATUS 61
8.6.2 C ORRECTIVE POWER 61
8.6.3 C APACITOR STAGES TABLE 62
8.6.4 C APACITOR STAGES RATING DIAGRAM 62
8.6.5 S WITCH CYCLE DIAGRAM 62
8.6.6 V OLTAGE AND CURRENT HARMONICS DIAGRAM 63

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8.6.7 VOLTAGE AND CURRENT HARMONICS TABLE 63
8.6.8 MANUAL FREQUENCY ANALYSIS 64
8.7 ABOUT PQC SUBMENU 65
8.8 FACTORY DEFAULT SETTINGS 65
8.9 UPDATE 69
9 INSTRUMENT VERSIONS 70
10 MAINTENANCE 72
10.1 CLEANING 72
11 DECOMMISSIONING AND REMOVAL, STORAGE AND
DISPOSAL 73
11.1 DECOMMISSIONING AND REMOVAL 73
11.2 STORAGE 74
11.3 DISPOSAL 75
12 GENERAL OPERATION 76
12.1 TROUBLESHOOTING 76
13 SCOPE OF SUPPLY 78
Figures
Figure 1 PQC dimensions in mm ............................................................................................ 15
Figure 2 Connection diagram for PQC 1202401-XX ............................................................. 24
Figure 3 Connection diagram for PQC 1202403-XX ............................................................. 25
Figure 4 Connection diagram for PQC 0602401-XX ............................................................. 26
Figure 5 Connection diagram for PQC 1204801-XX ............................................................. 27
Figure 6 Connection diagram for PQC 1204803-XX ............................................................. 28
Figure 7 Connection diagram for PQC 0614801-XX ............................................................. 29
Figure 8 Part of the connection diagram for 400/415 V networks with no neutral conductor 30
Figure 9 Part of the connection diagram for 690 V networks with a neutral conductor ........ 30
Figure 10 PQC Start screen (firmware version number may be different) ........................... 32
Figure 11 Menu structure 1 ................................................................................................... 36
Figure 12 Menu structure 2 ................................................................................................... 37
Figure 13 Menu structure 3 ................................................................................................... 37
Figure 14 Main menu 1/3 ..................................................................................................... 38
Figure 15 Main menu 2/3 ..................................................................................................... 38
Figure 16 Main menu 3/3 ..................................................................................................... 38
Figure 17 Changing the working language ........................................................................... 39
Figure 18 Identification: Stage + Connection ....................................................................... 40

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Figure 19 Identification: Connection .................................................................................... 40
Figure 20 Identification: Connection submenu .................................................................... 40
Figure 21 Identification: Stage ............................................................................................. 40
Figure 22 Identification: Stage submenu .............................................................................. 40
Figure 23 Identification: Manual .......................................................................................... 40
Figure 24 Identification: Manual submenu ........................................................................... 40
Figure 25 Connection identification started ......................................................................... 41
Figure 26 Capacitor stage identification started ................................................................... 41
Figure 27 Start-up completed ............................................................................................... 41
Figure 28 PQC overview L1 (1-phase) ................................................................................. 42
Figure 29 PQC overview L1 (3-phase) ................................................................................. 42
Figure 30 Capacitor stage statuses (1-phase, 6 stages) ......................................................... 42
Figure 31 Capacitor stage statuses (3-phase, 12 stages) ....................................................... 42
Figure 32 Control diagram .................................................................................................... 44
Figure 33 Control diagram with additional information ....................................................... 44
Figure 34 Zoomed in on control diagram ............................................................................. 44
Figure 35 Manual control ..................................................................................................... 45
Figure 36 Manual control enabled ........................................................................................ 45
Figure 37 Manual control: Switch out stages ....................................................................... 45
Figure 38 Manual control: Stages menu ............................................................................... 46
Figure 39 Example of a selected stage ................................................................................. 46
Figure 40 Message on failed attempt to switch in a stage .................................................... 47
Figure 41 Settings ................................................................................................................. 47
Figure 42 Control profiles .................................................................................................... 49
Figure 43 Control profile parameters ................................................................................... 49
Figure 44 Control response after setting target cos ϕ = 1, limitation = 0, parallel shift = 0 50
Figure 45 Control response after setting target cos ϕ = 0.92, limitation = 0, parallel shift = 0
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Figure 46 Control response after setting target cos ϕ = 1, limitation = 0, parallel shift = +1.0
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Figure 47 Control response after setting target cos ϕ = 0.92 ind, limitation = OFF, parallel
shift = -1.0 51
Figure 48 Control response after setting target cos ϕ = 0.92 ind, limitation = +1.0 ............ 52
Figure 49 Control response after setting target cos ϕ = 0.92 ind, limitation = +1.0, parallel
shift = -1.0 52
Figure 50 Control response after setting target cos ϕ = 0.95 cap, limitation = -1.0, parallel
shift = 0 53
Figure 51 Phase L1 is the control phase ............................................................................... 53
Figure 52 General settings menu .......................................................................................... 54
Figure 53 Capacitor stages .................................................................................................... 55
Figure 54 Set limits 1/2 ......................................................................................................... 56
Figure 55 Set limits 2/2 ......................................................................................................... 56
Figure 56 Change set limit for switching cycle counter ....................................................... 56
Figure 57 Alarm management .............................................................................................. 57
Figure 58 Alarm management; here the Display alarm option ............................................. 57
Figure 59 Extensions menu .................................................................................................. 58
Figure 60 Modbus configuration .......................................................................................... 58
Figure 61 Factory default settings ........................................................................................ 59
Figure 62 Password prompt .................................................................................................. 60
Figure 63 Info / status 1/3 ..................................................................................................... 60
Figure 64 Info / status 2/3 ..................................................................................................... 60

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Figure 65 Info / status 3/3 ..................................................................................................... 60
Figure 66 PQC status overview ............................................................................................ 61
Figure 67 Total corrective power Q ...................................................................................... 61
Figure 68 Capacitor stages table ........................................................................................... 62
Figure 69 Diagram showing all stages at 100% ................................................................... 62
Figure 70 Diagram showing corrective power of all stages ................................................. 62
Figure 71 Switch cycle diagram ........................................................................................... 62
Figure 72 Current harmonics diagram, y-axis 100% ............................................................ 63
Figure 73 Current harmonics zoomed in, y-axis 25% .......................................................... 63
Figure 74 Voltage harmonics table ....................................................................................... 63
Figure 75 Manual frequency analysis ................................................................................... 64
Figure 76 About PQC ........................................................................................................... 65
Tables
Table 1 Connection types for current transformers in L1, L2 and L3 ................................... 33
Table 2 c/k settings at 400 V AC and 50 Hz ......................................................................... 34
Table 3 Key functions ........................................................................................................... 35
Table 4 Factory default settings ....................................................................................... 62
Table 5 Instrument versions ............................................................................................. 67
Formulas
Formula 1 Calculation of c/k ................................................................................................. 34

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1 Safety
1.1 OBJECTIVE
This operating manual has been prepared for persons who install, connect, commission and operate
the PQC Power Quality Controller.
1.2 SAFETY INSTRUCTIONS
No claims under guarantee shall be valid in the event of damages caused by failure
to observe the instructions in this operating manual. We shall not be held liable for
consequential damages!
Incorrect operation or failure to observe the safety instructions will invalidate all
claims under the guarantee, and no liability is accepted for any injuries to persons
or damages to assets arising therefrom or occasioned thereby!
DANGER!
The following instructions must be observed to prevent danger to life and limb or damage
to equipment and other assets:
• Installation and commissioning of the instrument in industrial plant must be
carried out in strict compliance with the standards IEC 61508 and DIN VDE
0801.
• Any other laws, standards, regulations and safety rules (IEC, EN, VDE, etc.)
relevant to this product and the protection of persons and assets must be
observed. In Germany, it is essential to comply with the Equipment Safety Act
(GSG) and the regulations of the German Social Accident Insurance Institutions.
In other countries, the equivalent local regulations must be followed.
• Installation, commissioning, modifications and retrofitting may only be carried out
by appropriately qualified personnel.
• In Germany, it is essential to comply with the regulations of the Social Accident
Insurance Institution covering electrical installations. In other countries, the
equivalent local regulations must be followed.
• The instrument contains live components at the AC supply voltage and must
therefore not be opened.
• If the instrument is visibly damaged, it must not be installed, connected or
commissioned.
• Only approved installation cables must be used.
• If the instrument does not work after commissioning, it must again be isolated
from the power supply.
• The instrument must only be employed on duties up to the specified maximum
power. Overloading the instrument can result in its destruction, create a fire
hazard or cause an electrical accident. The load ratings for the various
connections must not be exceeded.
• Do not expose the instrument to direct sunlight or high temperatures, as these
could damage it or shorten its service life.
• Do not install the instrument near to sources of heat such as radiators or other
devices that generate heat.

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• Do not expose the instrument to rain, water, dampness or high levels of humidity.
Avoid direct contact with water at all cost.
• Failure to observe the safety instructions can result in death, serious injury or
severe damage to equipment and other assets.
• In commercial premises, the local accident prevention regulations must be
complied with (e.g. in Germany, the regulations of the German Social Accident
Insurance Institutions for electrical installations and equipment).
• The safety of the system in which the PQC is incorporated is the responsibility of
the persons installing and operating the system.
• For safety reasons and to retain conformity with product approval requirements
(CE marking), the user is not permitted to convert or otherwise modify the
instrument.
• The instrument must always be handled with due care; if it is jolted, knocked or
dropped from even a low height, it will be damaged.
• This operating manual may be changed without notification. Please consult our
website www.schrack.com for the up-to-date version.
When work is carried out on the instrument terminals and connecting cables, there is a
risk of live components being touched inadvertently. The working voltage may present a
hazard to health or may even be life-threatening.
The risk to life and limb can be significantly reduced by observing the above safety
precautions.
• The user must ensure that all operators are familiarized with this operating manual and follow it at all
times.
• This operating manual must be read through carefully and completely before the instrument is installed,
connected, commissioned and operated. All actions taken must be in accordance with this operating
manual.
• The operating manual must be held for future reference.
• Wherever this symbol is shown, the documentation must be referred to.
1.3 INTENDED USE
The PQC Power Quality Controller is intended for the following applications within the scope of the
technical data (see Section 2, Technical data):
• Control of reactive power in stages. Output relays (switched outputs, stages) are provided for this purpose.
Capacitors can be connected to these via current-amplifying electromechanical devices (relays, contactors).
• Measurement of data relevant to network power quality, such as voltage, current and frequency, either in any
desired phase ‘L1’ or in all three phases L1, L2 and L3, depending on the instrument version (see Section 2,
Technical data); connection of an alarm contact rated within the allowable limits for the electrical parameters (see
Section 2, Technical data)
The PQC is intended for installation in stationary, weather-protected control cabinets and enclosures located
indoors. Exposure to dampness is not permitted. The instrument is installed vertically, usually on the outside of
the control cabinet or enclosure, so that the controls and display are accessible to the operator.
The USB port is a service interface provided solely for updating the PQC firmware. Users are not permitted to use
this USB port for any other purpose, and therefore must not connect any cable or device to it. When the PQC is in
operation, the USB port must not be touched. It is intended for connecting a battery-powered notebook.
1.4 IMPROPER USE
Any use of the instrument that deviates from its intended use is considered improper and therefore not
permitted. If the PQC is used in a way not specified in this operating manual, the protection supported
by the instrument may be adversely affected.

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1.5 REPAIR
Repairs may not be carried out by the customer or user. Should repair work be necessary, the customer
or user must contact Schrack Technik (contact addresses see: www.schrack.com):
1.6 SYMBOLS USED
Special instructions in this operating manual are marked by symbols.
The corresponding word that expresses the extent of the danger is also printed above the instructions.
In order to avoid accidents, death or injury and damage to assets, these instructions must be complied
with at all times.
Warning signs
DANGER!
Indicates an immediate danger that if not avoided can result in death or serious injury.
DANGER!
Indicates an immediate danger of electric shock that if not avoided can result in death or
serious injury.
Notes for the correct functioning of the instrument
CAUTION!
These instructions indicate dangers that could result in damage to equipment if the
instructions are not followed.
They can also cover aspects of environmental protection.
NOTE!
These instructions, when followed, serve to ensure the correct functioning and fault-free
operation of the instrument.

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2 Technical data
Power supply
• Supply voltage PQC version: PQC xxx240x-xx:
85–267 V AC (absolute limits), frequency 45–65 Hz or
100–377 V DC (absolute limits)
PQC version: PQC xxx480x-xx:
85–530 V AC (absolute limits), frequency 45–65 Hz or
100–750 V DC (absolute limits)
• Power draw maximum 5 VA
• Overcurrent protection External, maximum 2 A (slow-blow) specified
Inputs
• Voltage path measurement inputs PQC version: PQC xxxxxx1-xx: single phase
PQC version: PQC xxxxxx3-xx: 3-phase
3-phase 80 V AC – maximum 760 V AC (phase–phase,
absolute limits), this corresponds to 115–690 V AC networks,
electrically interconnected via high resistance, medium
voltage measurement via ../100 V transformer possible
Power failure detection after duration of a half-wave
• Current path measurement inputs PQC version: PQC xxxxxx1-xx: single phase
PQC version: PQC xxxxxx3-xx: 3-phase
x/5 A AC or x/1 A AC (transformer secondary current ≥ 15
mA), electrically isolated, power draw maximum 1 VA per
transformer connection, continuous overload rating up to 6 A
AC, transient overload maximum 10 A AC for 10 seconds
• Digital inputs and outputs PQC version: PQC xxxxxxx-x1:
Up to 5 × 5–24 V DC inputs, alternatively usable as up to
5 × 24 V DC, 100 mA outputs, electrically interconnected with
each other and the temperature input
• Temperature inputs PQC version: PQC xxxxxxx-x1:
1 × Pt100 or Pt1000 RTD, 4-wire or 2-wire configuration,
automatic detector type identification
2× NTC thermistor type TDK/Epcos-B57861S0502F040,
type No. 29-20094
Measurement range -50 – 200 °C
Electrically connected with the digital outputs
Outputs
• Output relays (control outputs,
capacitor stages)
Normally open with common pole P
PQC version: PQC 120xxxx-xx: 12 output relays and
PQC version: PQC 060xxxx-xx: 6 output relays,
AC-14 250 V AC, maximum 3 A or DC-13 30 V DC, maximum
3 A, mechanical service life 2 x 107 switching cycles,
electrical service life AC-14 at 3 A 1 x 105 switching cycles,
AC-14 at 0.5 A 2 x 106 switching cycles
PQC version: PQC 061xxxx-xx: 6 output relays
AC-14 440 V AC, maximum 3 A or DC-13 125 V DC,
maximum 3 A, mechanical service life 1 x 107 switching
cycles,
electrical service life AC-14 at 3 A 1 x 105 switching cycles,
AC-14 at 0.5 A 2 x 106 switching cycles